more on big charges in a rifled musket
Gator Weiss, I'll take on #4 first.
Yes, ramming a ball
can distort the face. Tests have shown it is the base of the ball that is most important to maintaining accuracy. Consistent loading with a proper tip on the rod is the best way to avoid messing your ball. For hunting situations, a looser ball/patch combo is usually used anyway and you are not going to lose enough accuracy to matter.
#3: To be sure what I was talking about, since I am not a big time CW rifled musket shooter, I looked up something that was written by a friend of mine.
BTW, my area of interest is 16th & 17th century flintlock rifles. As far as I'm concerned, those preecussin thingys ain't been invented yet.
In the book compiled and edited by my, now deceased, good friend Don Davis, Winning and Shooting With the Champions, he had Bob Butcher write a chapter on shooting the rifled musket.
Bob, in those days (late 1960s through early 1980s) won many-many National championships with the rifled musket. Accepting what he says is a wise way to go.
He came to his conclusions by extensive testing. I have been there watching, by "extensive" I mean EXTENSIVE, days and days shooting all day, taking notes, trying powders, charges, voo-doo chants
and any thing else you can imagine.
In the end, his winning combo was "proper lube", he lists many and doesn't seem too fussy except to avoid some, like Crisco; a 50-60 gr. charge of bp and the right bullets. About minie choice, he says, "The only two minie bullets I can recommend and I have tried them all, are the .58 cal. 575213 or the 575213OS. I like the old style (OS) the best. It's a lighter bullet and has a thicker skirt than the 575213, which has less tendency to break off or crack while firing causing 'flyers' or tumbling bullets - go 575213OS."
As to your idea to harden the minie to avoid over expansion of the skirt when using larger charges, I'll add my opinion that this would prove to be a futile experiment.
It would require: exactly consistent hardness from batch to batch when casting and Butcher-like extensive testing on the benchrest. You would make the lead and powder suppliers very happy indeed.
And, I'll remind you, the CW rifled musket was designed to INCREASE felt recoil. Heavy thumping on the shoulder a hundred or two hundred times a day ain't fun. You would not like it.
Bob won matches that included 100 and 200 yard offhand targets. The inventors of the CW rifled musket did a good thing. The design does what it was intended to do and it does it well.
I guarantee, if you can hit a deer, using stock open sights, shooting offhand at 200 yards, it ain't goin' no wheres after that 505 grain hunka lead hits him.
Did I miss any of your questions?
My bottom line advice is do what works for you as long as it is within safe parameters.